Battery pack power transfer adaptor

ABSTRACT

A battery pack power transfer adaptor and a battery pack system that includes a battery pack adaptor. The adaptor enables a battery pack to provide high level power transfers to a variety of devices and to receive high level power transfers from a variety of power sources. The adaptor includes a battery pack interface to enable the adaptor to mechanically and electrically connect to the battery pack. The adaptor is able to transfer power at a variety of levels dependent upon the device to which it is attached.

RELATED APPLICATIONS

This application is a divisional application of and claims priority toU.S. patent application Ser. No. 17/237,929, filed on Apr. 22, 2021,titled, “Battery Pack Power Transfer Adaptor,” which in turn claimspriority under 35 U.S.C. § 119(e) to U.S. Provisional Patent ApplicationNo. 63/013,909, filed Apr. 22, 2020, titled “Battery Pack Power TransferAdaptor.”

TECHNICAL FIELD

This application relates to a battery pack system and a method fortransferring power to and/or from the battery pack. In oneimplementation, the system is configured to include an adaptor fortransferring power to and/or from a device coupled to the battery packthrough the adaptor.

BACKGROUND

Removable, rechargeable, secondary battery packs are becoming ubiquitousas more and more devices become wireless to take advantage of theadvances in battery technology.

Such battery packs are commonly part of cordless power tool systems andare designed and configured to operate with a variety of cordless powertool, such as drills, circular saws and grinders, for example. Thebattery packs and the power tools include an interface system thatenables the battery pack to couple to the power tool, as is well knownin the art. Typically, these battery packs are charged using batterypack chargers that are designed and configured to charge specificbattery packs. These chargers are designed and configured to plug into awall outlet for access to alternating current (AC) mains line (utility)power or some other source of AC power, such as a generator. The abilityto use the aforementioned battery packs to power unrelated devices, suchas mobile phones or low power lights is also desirable.

There are adaptors that may be coupled to the rechargeable battery packsthat enable the battery pack to provide power to such unrelated devices.

SUMMARY

The power transfer adaptor is both a tool and a charger designed to takeadvantage of USB 3.1's new PD (Power Delivery) specification. Thefeature includes the ability to supply bidirectional power up to 100 W.Because the adaptor is bidirectional, it will have many of the sameproperties of both a tool and a charger. For example, as a charger theadaptor can accept power up to 100 W from Type C source devices,incorporating legacy charger interfaces, standards & best practices. Andfor example, as a tool the adaptor can discharge a rechargeable batterypack to charge and power various devices through its Type C Port up to100 W and through its Type A Port up to 12 W.

The adaptor leverages the Power Delivery (PD) or USB PD standard. The PDstandard that allows devices to send or receive power through its Type Cport (bidirectional power flow) up to 100 W and at varying voltage andcurrent profiles. These products allow for discrete voltages of 5, 9,12, 15, and 20V and currents up to 5 A. The PD standard uses a PDcontract to establish a relationship between the PD device (the adaptorin this case) and a connected device. The contract is an agreementbetween two PD devices connected via Type C Cable. There are manynuances but the most basic constraints for each device are: (1) thesource must establish and maintain the agreed upon voltage within +/−4%while sourcing all the way up to the agreed upon maximum current and (2)the sink may pull any amount of current from 0 A all the way up to themaximum agreed upon current. The current may not exceed the maximum formore than a few milliseconds.

A PD charger/provider/source is the device in the PD contract thatagrees to send power to its partner device. A PD consumer/load/sink isthe device in the PD Contract that agrees to accept power from itspartner device. A PD dual role port (DRP) device is a device that iscapable of being either a source or a sink depending on what isconnecting to and its internal state. The adaptor is a DRP device.

The adaptor can provide cordless USB “C” power delivery limited only bythe available battery packs, can choose a longer run time or shorter runtime battery pack to customize a user experience, and can choose alarger or a smaller battery pack size based on ergonomic preferences.

These and other advantages and features will be apparent from thedescription and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an example embodiment of a power transfer adaptor.

FIG. 2 is an exploded view of the power transfer adaptor of FIG. 1 .

FIG. 3 is an isometric view of an interior of a top housing of the powertransfer adaptor of FIG. 1 .

FIG. 4 is an example embodiment of a battery pack system including thepower transfer adaptor of FIG. 1 .

FIG. 5 is another example embodiment of a battery pack system includingthe power transfer adaptor of FIG. 1 .

FIG. 6 is another example embodiment of a battery pack system includingthe power transfer adaptor of FIG. 1 .

FIG. 7 is another example embodiment of a battery pack system includingthe power transfer adaptor of FIG. 1 .

FIG. 8 is another example embodiment of a battery pack system includingthe power transfer adaptor of FIG. 1 .

FIG. 9 is another example embodiment of a battery pack system includingthe power transfer adaptor of FIG. 1 .

FIG. 10 is another example embodiment of a battery pack system includingthe power transfer adaptor of FIG. 1 .

FIG. 11 is another example embodiment of a battery pack system includingthe power transfer adaptor of FIG. 1 .

FIGS. 12 a and 12 b are additional example embodiments of a battery packsystem including the power transfer adaptor of FIG. 1 .

FIGS. 13 a and 13 b are additional example embodiments of a battery packsystem including the power transfer adaptor of FIG. 1 .

FIG. 14 is a simplified schematic circuit diagram of an example batterypack coupled to an example power transfer adaptor.

FIG. 15 is a simplified schematic circuit diagram of an example batterypack coupled to an example power transfer adaptor.

FIG. 16 is a front elevation view of a battery pack of the presentinvention.

FIG. 17 is a right, side elevation view of the battery pack of FIG. 16 .

FIG. 18 is a rear elevation view of the battery pack of FIG. 16 .

FIG. 19 is a left, side elevation view of the battery pack of FIG. 16 .

FIG. 20 is a top plan view of the battery pack of FIG. 16 .

FIG. 21 is a bottom plan view of the battery pack of FIG. 16 .

FIG. 22 is a front, top, right-side isometric view of the battery packof FIG. 16 .

FIG. 23 is a rear, top, right-side isometric view of the battery pack ofFIG. 16 .

FIG. 23 is a rear, top, left-side isometric view of the battery pack ofFIG. 16 .

FIG. 24 is a rear, top, right-side isometric view of the battery pack ofFIG. 16 .

FIG. 25 is a front, top, left-side isometric view of the battery pack ofFIG. 16 .

FIG. 26 is a front, bottom, right-side isometric view of the batterypack of FIG. 16 .

FIG. 27 is a rear, bottom, right-side isometric view of the battery packof FIG. 16 .

FIG. 28 is a rear, bottom, left-side isometric view of the battery packof FIG. 16 .

FIG. 29 is a front, bottom, left-side isometric view of the battery packof FIG. 16 .

DETAILED DESCRIPTION

FIGS. 1-3 illustrate an example embodiment of a battery pack powertransfer adaptor 10. The adaptor 10 may include a housing 12. Thehousing 12 may include an upper housing 14 and a lower housing 16. Thelower housing 16 may include a first side housing 16 a and a second sidehousing 16 b. The upper housing 14 and the lower housings 16 a, 16 b maybe coupled together by a plurality of fasteners 18, such as screws.

The upper housing 14 and the lower housing 16 form a cavity when coupledtogether. The adaptor 10 may include a variety of electrical andelectronic components in the cavity. For example, the adaptor 10 mayinclude a printed circuit board (PCB) 20 including a plurality ofcomponents 22, such as resistors, capacitors, connectors, integratedcircuits, etc., mounted to the PCB 20. The adaptor 10 may also include aterminal block 24 in the cavity. The terminal block 24 may include ahousing 26 and a plurality of adaptor terminals 28 fixedly positioned inthe housing 26. The adaptor 10 may also include a plurality of wires 30coupling one or more of the plurality of terminals 26 to the PCB 20. Theadaptor 10 may also include a belt clip 31 coupled to the upper housing14. The upper housing 14 may also include a plurality of connectoropenings 32 a, 32 b for providing access to connectors (ports) 34 a, 34b coupled to the PCB 20. The adaptor may include a USB Type C port 34 aand a USB Type A port 34 b. In an alternate embodiment, the adaptor 10may include a second USB Type C port instead of the USB Type A port. Inanother alternate embodiment, the adaptor 10 may include ports—eitherUSB Type A, USB Type B or USB Type C—in addition to the two portsillustrated.

Generally, the adaptor 10 operates with a removable battery pack. Thisenables the adaptor 10 to provide power to a variety of products anddevices from a variety of battery packs. The adaptor 10 is able toprovide bi-directional power transfer with the detachable battery pack.The adaptor may include terminals 28 to voltage tap the plurality ofbattery cells in the detachable battery pack and provide access to thevoltage tap values. The adaptor 10 includes an automatic sleep mode inresponse to an undervoltage condition, an idle condition, a no cableattached condition and for various fault conditions. The adaptor 10 mayalso include a wake-up feature for a cable insertion condition. Theadaptor 10 includes a peak current control monitor circuit to ensurethat the current into or out of the adaptor 10 does not exceedpre-established values.

FIG. 4 illustrates an example power tool and battery pack system. Thesystem includes an example battery pack 100 and an example power tool110. The removable battery pack 100 provides power to the power tool110. As is well known in the art, the battery pack 100 and the powertool 110 include an interface system for coupling the battery pack 100to the power tool 110. This example system uses a “slide” type interfacesystem in which the battery pack 100 includes a set of rails and groovesand a latch to interface with a corresponding set of rails and groovesand a latch recess included on the power tool 110. Other types ofinterface systems, for example a “tower” type interface system couldalso be used. Once the battery pack 100 is coupled to the power tool110, the battery pack 100 can supply power to the power tool 110 foroperation of the power tool 110. Once the battery pack 100 is drainedfrom operating the power tool 110, the battery pack 100 can be removedfrom the power tool 110 and coupled to the adaptor, as described below,to charge the battery pack 110.

The adaptor 10 includes interface features similar to the power tool 110to enable the adaptor 10 to couple to the battery pack 100. For example,the adaptor 10 includes a set of rails 36 and a set of grooves 38 and alatch recess 40. The system may also include a bi-directional USB Type Ccord 42 include a USB Type C male connector 44 a, 44 b at each end ofthe cord 42. The system may also include a plug-in power supply orrectifier 46 including a USB Type C port 48. In this system, one maleconnector 44 a of the cord 42 plugs into the USB Type C port 34 a of theadaptor 10 and one male connector 44 b of the cord 42 plugs into the USBType C port 48 of the power supply 46. The power supply 46 plugs into anoutlet coupled to an AC power source, for example, a utility mains lineor a portable generator. In this manner, the adaptor 10 is able toprovide a charge to the battery pack 100 from the outlet.

Alternatively, the adaptor 10 may be coupled to a DC power source.Specifically, the male connector 44 b of the USB Type C cord 42 may becoupled to a USB Type C port 50 in an automobile 52 to source power froma battery or alternator in the automobile 52.

FIG. 5 illustrates another example power tool and battery pack system.The system includes a battery pack 100, an adaptor 10, a bi-directionalUSB Type C cord 42, and a motorized electronic device 120. The batterypack 100, the adaptor 10, and the cord 42 are as described above. Themotorized electronic device 120 includes a motor (not shown) and anapplication tool, for example a grinder. The device 120 includes a USBType C port 122. The adaptor 10 couples to the battery pack 100. Thecord 42 plugs into the USB Type C port of the adaptor 10 and into theUSB Type C port of the device 120. The motorized electronic device 120may (a) be without a battery and DC power from power transfer adaptor 10drives the motor or (b) have a small battery inside the device 120 thatruns the device 120 and the power transfer adaptor 10 charges thebattery (either while in use or while idle—so device 120 could beoperated either when connected to the adaptor 10, i.e., corded, or whennot connected to the adaptor 10, i.e., cordlessly) or (c) have a batterywhich runs the DC motor and the power transfer adaptor 10 only chargesthe battery when the device 120 is not in use.

FIG. 6 illustrates an example computing device and battery pack system.The system includes a battery pack 100, an adaptor 10, a bi-directionalUSB Type C cord 42 and a computing device 130, for example a tabletcomputing device or a mobile phone. The battery pack 100, the adaptor10, and the cord 42 are as described above. The computing device 130includes a processor and other electrical and electronic components (notshown). The device 130 includes a USB Type C port 132. The adaptor 10couples to the battery pack 100. The cord 42 plugs into the USB Type Cport of the adaptor 10 and into the USB Type C port of the device 130.The computing device 130 may (a) be without a battery and DC power frompower transfer adaptor 10 drives the processor and other electrical andelectronic components or (b) have a small battery inside the device 130that runs the device 130 and the power transfer adaptor 10 charges thebattery (either while in use or while idle—so device 130 could beoperated either when connected to the adaptor 10, i.e., corded, or whennot connected to the adaptor 10, i.e., cordlessly) or (c) have a batterywhich runs the processor and other electrical and electronic componentsand the power transfer adaptor 10 only charges the battery when thedevice 130 is not in use.

FIG. 7 illustrates an example non-motorized electronic device andbattery pack system. The system includes a battery pack 100, an adaptor10, a bi-directional USB Type C cord 42 and a non-motorized electronicdevice 140, for example a head lamp or a radio. The battery pack 100,the adaptor 10, and the cord 42 are as described above. Thenon-motorized electronic device 140 includes a load such as a light oran amplifier and other electrical and electronic components (not shown).The device 140 includes a USB Type C port 142. The adaptor 10 couples tothe battery pack 100. The cord 42 plugs into the USB Type C port of theadaptor 10 and into the USB Type C port of the device 140. Thenon-motorized electronic device 140 may (a) be without a battery and DCpower from power transfer adaptor 10 drives the light and otherelectrical and electronic components or (b) have a small battery insidethe device 140 that runs the device 140 and the power transfer adaptor10 charges the battery (either while in use or while idle—so device 140could be operated either when connected to the adaptor 10, i.e., corded,or when not connected to the adaptor 10, i.e., cordlessly) or (c) have abattery which runs the light and other electrical and electroniccomponents and the power transfer adaptor 10 only charges the batterywhen the device 140 is not in use.

FIG. 8 illustrates another example battery pack system. The systemincludes a battery pack 100, an adaptor 10, and a motorized or anon-motorized electronic device 150, for example a fan or a wirelessspeaker. The battery pack 100 and the adaptor 10 are as described above.The motorized or non-motorized electronic device 150 includes a loadsuch as a motor—in the case of a motorized device—or a speaker—in thecase of a non-motorized device and other electrical and electroniccomponents (not shown). The device 150 includes a USB Type C connector152. The adaptor 10 couples to the battery pack 100. The device 152plugs into the USB Type C port of the adaptor 10. The device 150 may bedirectly mountable onto the USB Type C port 32 a of the adaptor 10without a cord 42. The device 150 may include a set of rails and groovesor the weight of the device 150 secures the device 150 to the adaptor10. The motorized or non-motorized electronic device 150 may (a) bewithout a battery and DC power from power transfer adaptor 10 drives thelight and other electrical and electronic components or (b) have a smallbattery inside the device 150 that runs the device 150 and the powertransfer adaptor 10 charges the battery (either while in use or whileidle—so device 150 could be operated either when connected to theadaptor 10, i.e., corded, or when not connected to the adaptor 10, i.e.,cordlessly) or (c) have a battery which runs the motor or speaker andother electrical and electronic components and the power transferadaptor 10 only charges the battery when the device 150 is not in use.

FIG. 9 illustrates another example battery pack system. This systemincludes a plurality of battery packs 100 and a plurality of adaptors 10and a plurality of USB Type C cords 42. In this system, the adaptors 10couple to the battery packs as described above. In a first embodiment,the adaptors 10 include a single USB Type C port 32 a. As such, thefirst connector 44 a of the cord 42 is coupled to the USB Type C port 32a of the first battery pack 100 and the second connector 44 of the cord42 is coupled to the USB Type C port 32 of the second battery pack 100.In this configuration, the charge of the two battery packs 100 will bebalanced between the two battery packs. In an alternate embodiment, theadaptor 10 includes two USB Type C ports. In such a configuration, morethan two battery packs 100 can be daisy-chained together and a firstbattery pack in the line of battery packs 100 can be plugged into an ACpower source—as illustrated in the system of FIG. 4 —to provide power toall of the battery packs 100.

FIG. 10 illustrates another example battery pack system. This systemincludes a battery pack 100 of a first company A and an adaptor 10designed and configured to couple to the Company A battery pack 100 anda battery pack 100 from a second company B and an adaptor 10 designedand configured to couple to the Company B battery pack 100. The systemalso includes a desktop charger 160. The charger 160 includes a pair ofUSB Type C ports. The charger is designed and configured to include aplug for coupling to a supply of AC power, as described above, and toprovide charging power at both USB Type C ports. The system alsoincludes a pair of bi-directional USB Type C cords 42. This systemallows a variety of company battery packs 110A, 110B to be charged fromthe charger of one of the Company A or B or from another Company C. Inthis system, the first male connector 44 a of the first cord 42 couplesto the USB Type C port 32 a of the Company A battery pack 100A and thesecond male connector 44 b of the first cord 42 couples to a first USBType C port of the desktop charger 160 and the first male connector 44 aof the second cord 42 couples to the USB Type C Port 32 a of the CompanyB battery pack 100B and the second male connector 44 b of the secondcord 42 couples to a second USB Type C port of the desktop charger 160.As such, the desktop charger 160 can provide a charging power to boththe battery packs 100A, 100B, either serially or simultaneously.

FIG. 11 illustrates another example battery pack system. This systemincludes a battery pack 100, an adaptor 10, a cord 42 and a computingdevice 170 that includes a USB Type C port. The battery pack 100, theadaptor 10, the cord 42 and the computing device 170 couple as describedabove. In this example system, data regarding the battery pack may betransferred through the adaptor 10 via the USB Type C connection to thecomputing device 170. The computing device 170 may adjust the chargingscheme from the battery pack 100 to the computing device 170. Thecomputing device 170 may make these adjustments using an internal,self-operating software application or a user may make these adjustmentsusing a user-driven application loaded on the computing device. Thecomputing device 170 may transfer data or program code to the batterypack 100. Alternatively, the computing device 170 may include adiagnostic application. As such, when the computing device 170 iscoupled to the adaptor 10 and the adaptor 10 is coupled to a batterypack 100 that has been returned to a manufacturer, the computing devicecan read diagnostic or data logging information regarding the health ofthe battery pack 100 and any information regarding any failures in thebattery pack. A user can than use the computing device 170 to determinethe cause underlying the failure of the battery pack 100.

FIG. 12A illustrates another example battery pack system. This systemincludes a battery pack 100, an adaptor 10, two cords 42 and two powersupplies 46. In this system the adaptor 10 includes two USB Type Cports. The first male connector 44 a of the first cord 42 is pluggedinto the first USB Type C port of the adaptor 10 and the second maleconnector 44 b of the first cord 42 is plugged into the USB Type C portof the first power supply 46. The first male connector 44 a of thesecond cord 42 is plugged into the second USB Type C port of the adaptor10 and the second male connector 44 b of the second cord 42 is pluggedinto the USB Type C port of the second power supply 46. Both powersupplies 46 are plugged into a source of AC power. In this system, thebattery pack 100 is supplied two times as much power than if only asingle power supply were coupled to the adaptor 10 and as such, thebattery pack 100 can be charged twice as fast.

FIG. 12B illustrates another example battery pack system. This systemincludes a battery pack 100, an adaptor 10, a single cord 42′ and asingle power supply 46. In this system the adaptor 10 includes two USBType C ports. The cord 42′ includes three male connectors 44 a, 44 b, 44c. The first male connector 44 a of the cord 42′ is plugged into thefirst USB Type C port of the adaptor 10, the second male connector 44 bof the cord 42′ is plugged into the second USB Type C port of theadaptor 10 and the third male connector 44 c of the cord 42′ is pluggedinto the USB Type C port of the power supply 46. As the power supply 46is able to provide power to two USB Type C ports on the adaptor 10 thebattery pack 100 is supplied two times as much power than if only asingle USB Type C port of the adaptor 10 were being used and as such,the battery pack 100 can be charged twice as fast.

FIG. 13A illustrates another example battery pack system. This systemincludes a battery pack 100, an adaptor 10, two cords 42 and twocomputing devices 180, each with USB Type C ports. In this system theadaptor 10 includes two USB Type C ports. The first male connector 44 aof the first cord 42 is plugged into the first USB Type C port of theadaptor 10 and the second male connector 44 b of the first cord 42 isplugged into the USB Type C port of the first computing device 180. Thefirst male connector 44 a of the second cord 42 is plugged into thesecond USB Type C port of the adaptor 10 and the second male connector44 b of the second cord 42 is plugged into the USB Type C port of thesecond computing device 180. In this system, the battery pack 100 isable to supply charging power to two computing devices 180 and chargethem both simultaneously.

FIG. 13B illustrates another example battery pack system. This systemincludes a battery pack 100, an adaptor 10, a single cord 42′ and acomputing device 180 with a USB Type C port. In this system the adaptor10 includes two USB Type C ports. The cord 42′ includes three maleconnectors 44 a, 44 b, 44 c. The first male connector 44 a of the cord42′ is plugged into the first USB Type C port of the adaptor 10, thesecond male connector 44 b of the cord 42′ is plugged into the secondUSB Type C port of the adaptor 10 and the third male connector 44 c ofthe cord 42′ is plugged into the USB Type C port of the computing device180. As the battery pack 100 is able to provide twice as much chargingpower to the computing device 180 through two USB Type C ports of theadaptor 10 the computing device 180 is supplied two times as much powerthan if only a single USB Type C port of the adaptor 10 were being usedand as such, the computing device 180 can be charged twice as fast.

FIG. 14 illustrates a simplified schematic circuit diagram of an examplebattery pack 500 coupled to an example power transfer adaptor 600. Theexample battery pack 500 includes a battery module (sometimes alsoreferred to as a battery circuit) 510. The battery module 510 includes,among other components not illustrated for purposes of simplicity butunderstood to those of ordinary skill in the art, a plurality of batterycells 520. The battery cells 520 are coupled together in a first stringof battery cells 530A (sometimes also referred to as a set of batterycells) and a second string of battery cells 530B. Each string of batterycells 530A, 530B includes five battery cells connected in series. Inalternate embodiments, the strings of battery cells may have fewer ormore battery cells. Each string of battery cells 530A, 530B includes apositive node A+, B+, respectively and a negative node A−, B−,respectively. The battery pack 500 also includes a plurality of batterypack terminals BT1-BT8 (sometimes also referred to as a set of batterypack terminals). The set of battery pack terminals includes a firstsubset of battery pack terminals BT1 and BT2 that serve as powerterminals for transferring power to charge the battery cells or power tooperate a device coupled to the battery pack, either directly or throughan adaptor 600. The set of battery pack terminals may also include asecond subset of battery pack terminals BT3-BT8. The second subset ofbattery pack terminals BT3-BT8 serve as signal or data terminals fortransferring low current, signals to indicate various pieces of dataregarding the battery pack. The battery pack also includes anovervoltage protection (OVP) module (sometimes referred to as a circuitor controller). The OVP module includes a connection to a node betweenadjacent battery cells. In this manner, the OVP module can determine ifa charge on each of the battery cells exceeds an overvoltage threshold.The OVP module is also coupled to the BT4 signal terminal. If one of theplurality of battery cells exceeds the overvoltage threshold, the OVPmodule outputs a signal to the BT4 signal terminal. The battery pack 500also includes an identification circuit (ID). The ID circuit isconnected to the BT4 signal terminal. The ID circuit includes variouscomponents, for example resistors and/or capacitors, coupled between avoltage and a ground reference. The values of the resistors and/orcapacitors determine the voltage value that is place on the BT4 signalterminal and are indicative of various characteristics of the batterypack, for example, its chemistry, capacity, cell type, etc. The batterypack 500 also includes a thermistor circuit (TH). The TH circuit isconnected to the BT3 signal terminal. The TH circuit includes variouscomponents, for example a thermistor, resistors and/or capacitorscoupled between a voltage and a ground reference. The thermistormonitors the temperature of the battery cells. If the temperature of oneor more of the battery cells exceed a temperature threshold, a signal isplaced on the BT3 terminal. The values of the capacitor(s) in the THcircuit may also indicate various characteristics of the battery pack,for example, the number of strings of battery cells in the battery pack.In this example battery pack, the strings of battery cells 530A, 530Bare connected together in parallel. As such, the A+ node and the B+ nodeare both connected to the BT2 power terminal and the A− node and the B−node are both connected to the BT1 power terminal.

The adaptor 600 includes a plurality of terminals TT1-TT8 (sometimesreferred to as a set of terminals). The set of adaptor terminalsincludes a first subset of adaptor terminals TT1 (negative powerterminal) and TT2 (positive power terminal) that serve as powerterminals for transferring power to charge or discharge the batterycells of a battery pack coupled to the adaptor 600. The set of adaptorterminals may also include a second subset of adaptor terminals TT3-TT8.The second subset of adaptor terminals TT3-TT8 serve as signal or dataterminals for transferring low current, signals to indicate variouspieces of data regarding an attached battery pack 500. The adaptor 600may include a first USB type C port. The adaptor 600 may include a firstUSB type A port. In alternate embodiments, the adaptor 600 may include asecond USB type C port instead of the USB type A port. The USB type Cport may include a first positive node, a second positive node, anegative node and data node. These nodes may be formed as terminals orpins on the port. The adaptor 600 may include an ideal diode coupled tothe first positive node of the type C port. The adaptor 600 may includea controllable switch coupled to the second positive node of the type Cport. The first positive node and the second positive node of the type Cport are coupled to the positive power terminal TT2 and the negativenode of the type C port is coupled to the negative power terminal TT1.

The adaptor 600 may include a first control module (sometimes alsoreferred to as a control circuit or a controller or a microcontroller orcontrol circuitry) and a second control module (sometimes also referredto as a control circuit or a controller or a microcontroller or controlcircuitry). The adaptor 600 may include a bi-directional non-invertingbuck/boost converter coupled between the positive power terminal TT2 andthe first and the second positive nodes of the type C port. Thebuck/boost converter may be coupled to the first control module. Theadaptor may include battery disconnect switch coupled between thebuck/boost converter and the positive power terminal TT2. The USB type Aport may include a positive node, a negative node and data node. Thesenodes may be formed as terminals or pins on the port. The adaptor 600may include an ideal diode coupled to the first positive node of thetype A port. The adaptor 600 may include a buck converter coupledbetween the positive power terminal TT2 and the positive node of thetype A port. The buck converter may be coupled to the second controlmodule. The adaptor may include a OVP module coupled to the adaptorpower terminals TT1, TT2 and to the adaptor signal terminals TT5-TT8.The OVP module may be coupled to the second control module. The adaptor600 may include a first thermistor circuit and a second thermistorcircuit to monitor the temperature of the adaptor 600 and itscomponents. The first and second thermistor circuits may be coupled tothe second control module.

The first control module may be coupled to the battery disconnect switchto control the battery disconnect switch based on various signalsreceived by the first control module. The first control module may beconnected to the TT4 signal terminal. The second control module may beconnected to the TT3 signal terminal. The second control module may becoupled to the control switch coupled to the second positive node of thetype C port. The second control module may control the control switchcoupled to the second positive node of the type C port based upon one ormore signals received by the second control module.

After a user inserts a source into the adaptor Type C port, the adaptorperforms a negotiation with the partner device. When negotiation iscomplete, a PD contract is established wherein the partner device Type Csource is obligated to provide the contract voltage and our unit isobligated to not exceed the agreed upon maximum current level. Typicalvoltage and current levels are as follows:

Voltage Level Current 5 V 1 A, 1.5 A, 3 A 9 V 1 A, 1.5 A, 3 A 12 V 1 A,1.5 A, 3 A 15 V 1 A, 1.5 A, 3 A 20 V 1 A, 1.5 A, 3 A, 5 A

The adaptor can read the PD contract information and adapt its currentintake accordingly.

Current Level Selection

When selecting a current level for charging, the adaptor will considerand comply with: the partner device (charger's) maximum current outputlevel (Ibus limit) and the battery's maximum safe allowable currentlevel (lbat limit). The adaptor's software is perpetually monitoringboth the PD/Type C activity to determine the lbus limit andbattery/ambient conditions to determine the lbat limit.

Partner Device & Ibus Limit

As mentioned above, the adaptor will attempt to pull currentcommensurate with the maximum current the partner device can supplyminus about 5%. This ensures we minimize charge time but do not exceedthe PD contract conditions.

Pack ID Limits

The adaptor reads and considers both the ID Resistor (ID line to ground)and the ID Capacitor (NTC line to ground) of the battery pack withindependent microcontrollers and chooses the lower of the two values toselect the maximum amount of current the battery pack can take whencharging the battery pack.

Charger NTC & Thermal Foldback

In order to prevent the adaptor from overheating, there is a thermalfoldback routine. To do this we read the two on-board NTCs and adjustthe battery current accordingly. The routine is as follows: at 115° C.we reduce the maximum allowable battery current from 4 A or higher to 2A maximum, at 95° C. we re-allow the maximum current to be 4 A or higher(pack dependent), at 125° C. we disallow current flow entirely, at 120°C. we re-allow current flow of 2 A.

Pack NTC Limitations

In order to protect the attached battery and comply with chargingschemes for the attached battery pack, the adaptor must react to thepack NTC conditions as follows: below 0° C., allow 0 A charging, between0° C. and 10° C., allow 2 A maximum charging, above 60° C. allow 0 Acharging; each options including a few degrees of hysteresis.

Over-Voltage Protection Reset Limits & Topping Off

The adaptor uses top-off “step down” charging schemes similar tocharger. The rule base is as follows: for bulk charge (0 OVP trips) pullthe maximum amount of current allowed by all the other rules (CNTC,Pack, lbus, Pack ID); after 1 OVP Reset: set the limit to 2 A; after 2OVP Resets: set the limit to 1 A. For all subsequent resets, set thelimit to 300 mA as a maintenance charge. However, if a Type A device isattached, the minimum current will be 2 A instead of 300 mA in order toensure that adaptor charges the attached battery pack at a rate that isfaster than the Type A discharge rate.

Type C Sourcing/Discharging

After a user inserts a sink into the adaptor Type C port, the adaptorperforms a contract negotiation with the partner device. When thecontract negotiation is complete, a PD contract is established whereinthe partner device Type C sink is obligated to pull less than the PDcontract maximum current and the adaptor is obligated to provide therequested voltage within +/−5%. If the battery pack NTC readingindicates a reading greater than 70° C. the adaptor will not allowdischarge through the Type C port. If one of the adaptor NTCs detects atemperature greater than 120° C. the adaptor will not allow dischargethrough the Type C port. If the adaptor detects a stack voltage of <15 Vit will cease to allow discharge on the Type C port. The adaptor willonly re-enable discharge once the stack voltage exceeds 17.8 V.

Type A Sourcing/Discharging

After a user inserts a Type A device into the Type A port of theadaptor, the adaptor detects the presence of a load and turns on theType A bus within ^(˜)1 s. If the adaptor temperature or the batterypack temperature falls below −20° C. the adaptor will stop current flowthrough the Type A port. If the adaptor detects a stack voltage of <15 Vit will stop discharge on the Type A port. The adaptor will onlyre-enable discharge once the stack voltage exceeds 15.5 V. The Type Abus will remain on for at least 8 hours. At that point the adaptorchecks whether a device is still inserted. If a device is still insertedto the Type A port, the adaptor keeps the bus on. If a device is notstill inserted to the Type A port, then the adaptor turns off the Type Aport.

Numerous modifications may be made to the exemplary implementationsdescribed above. These and other implementations are within the scope ofthis application.

1. A battery pack power transfer adaptor, comprising: a USB type C port;a set of power terminals including a positive power terminal and anegative power terminal, the set of power terminals configured to matewith a rechargeable battery pack for transferring power to and from thebattery pack; the positive power terminal coupled to the USB type C portat a first node and at a second node of the type C port and the negativepower terminal coupled to the USB type C port at a third node; a firstcontrol module and a second control module; and a bi-directionalnon-inverting buck/boost converter coupled between the positive powerterminal and the first and the second node of the type C port.
 2. Thebattery pack power transfer adaptor, as recited in claim 1, furthercomprising an overvoltage protection module coupled to the adaptorpositive power terminal and the adaptor negative power terminal and to aplurality of adaptor signal terminals.
 3. The battery pack powertransfer adaptor, as recited in claim 2, wherein the overvoltageprotection module is coupled to the second control module.
 4. Thebattery pack power transfer adaptor, as recited in claim 1, furthercomprising a first thermistor circuit and a second thermistor circuit tomonitor the temperature of the adaptor and its components.
 5. Thebattery pack power transfer adaptor, as recited in claim 4, wherein thefirst and second thermistor circuits are coupled to the second controlmodule.
 6. The battery pack power transfer adaptor, as recited in claim1, wherein the buck/boost converter is coupled to the first controlmodule.
 7. The battery pack power transfer adaptor, as recited in claim1, further comprising a battery disconnect switch coupled between thebuck/boost converter and the positive power terminal.
 8. The batterypack power transfer adaptor, as recited in claim 1, further comprising aUSB type A port, the USB type A port including a positive node, anegative node and data node formed as terminals on the port.
 9. Thebattery pack power transfer adaptor, as recited in claim 8, furthercomprising a buck converter coupled between the positive power terminaland the positive node of the type A port.
 10. The battery pack powertransfer adaptor, as recited in claim 9, wherein the buck converter iscoupled to the second control module.